Arcovers suck! You can also try lowering the primary coil a little to get less coupling, that sometimes helps. First sparks are always great! I wasn't so lucky my first go and scared the absolute shit out of myself shorting out the tank caps with my soldering iron. Lets just say that was enough TC work for that night

Annoyingly the primary coil wires were soldered to the board. To minimize inductance you had to keep them as short as possible, which means you could hardly take the top off the coil to get to the PCB. So I was trying to unsolder the primary connections, when my soldering iron melted through the gate driver transformer wires, dumped the cap bank into the IGBT gates and blew the ass out of them

After that experience I found a relay and a couple high power resistors and connected them up so the cap bank would drain automagically when you turned it off.

i think im getting secondary to shorting and secondary to the coil form pipe on the primary

think its a insulation problem on the secondary, my new insulation spray should be here 2moz

I am guessing what you are describing isn't racing sparks down the length of the secondary and terminating at the primary windings, is it?
If it is, that is most certainly a coupling issue with your primary windings. (overcoupling) I'd suggest either putting the windings level or just a mm or 2 below with the last turn on the secondary and or adj your topload. Too topload heavy/ too much capacitance. ( This was Things suggestion, and he's dead right!)

However looking at the video, I can't say I see this problem. Sounds rather healthy to my ears.

Ahhh ok, i had it tuned for the the new toroid while using the old smaller capacitance toroid. Its running really good atm, im pretty happy, with a tune of the primary should see some nice voltage gains

Ahhh ok, i had it tuned for the the new toroid while using the old smaller capacitance toroid. Its running really good atm, im pretty happy, with a tune of the primary should see some nice voltage gains

ahah!!! hmmm... So that's the problem. It wasn't tuned to old toroid because it was mismatched!! Got ya!!
Now you've got a superior toroid and a very healthy performing coil!!
Good to hear sheila got her spark back!!